System and method for packaging bales of hay and an improved wrapping apparatus

Abstract

A system for packaging hay bales includes a press for compressing hay to small, compact bales and a wrapping machine which applies multiple sheets of a thin material to form a package of an effective strength that maintains the form and integrity of the hay bales, and prevents them from expanding back to their pre-compressed size. The wrapping machine applies the thin film to successive compressed hay bales such that the material extends therebetween to integrate multiple hay bales into a common bundle. A partial cutting machine positioned downstream of the wrapping machine cuts a portion of the material between adjacent hay bales to provide a detachable seam. A full cutting machine positioned downstream of the partial cutting machine completely cuts the material between selected pairs of adjacent wrapped hay bales to define sets of multiple wrapped hay bales.

I claim: 
     
       1. A system for packaging bales of hay comprising: a wrapping machine having a conduit through which hay bales are extruded along a feed axis, the wrapping machine having means for wrapping multiple layers of material around the hay bales as the hay bales are extruded through and out of the conduit, the wrapping machine applying the layers of material to successive hay bales such that the material extends between adjacent wrapped hay bales; and   a pressing machine provided downstream of the wrapping machine to receive the wrapped hay bales, the pressing machine physically engaging and mechanically pressing against the layers of material and hay bales, squeezing the layered material together and against the hay bales to remove air pockets formed between adjacent layers of material.   
     
     
       2. A system according to claim 1 wherein the pressing machine comprises: a first pair of pressure rollers having an upper pressure roller positioned above the wrapped hay bales and a lower pressure roller positioned beneath the wrapped hay bales, the first pair of pressure rollers applying opposing forces to squeeze the wrapped hay bales along a first coordinate; and   a second pair of pressure rollers having a pressure roller positioned to the left of the wrapped hay bales and another pressure roller positioned to the right of the wrapped hay bales, the second pair of pressure rollers applying opposing forces to squeeze the wrapped hay bales along a second coordinate substantially perpendicular to the first coordinate.   
     
     
       3. A system according to claim 1 further comprising: a partial cutting machine provided downstream of the wrapping machine to receive the wrapped hay bales, the partial cutting machine forming a succession of slits along a line transverse to the feed axis through portions of the layered material between adjacent wrapped hay bales to provide a detachable seam between individual hay bales.   
     
     
       4. A system according to claim 1 further comprising: a full cutting machine positioned downstream of the wrapping machine, the full cutting machine completely cutting the layered material between selected pairs of adjacent wrapped hay bales.   
     
     
       5. A system according to claim 4 wherein the full cutting station comprises: at least two movable cutting blades mounted to opposite sides of the wrapped hay bales, individual blades having jagged teeth; and   means for operably moving the cutting blades toward one another from the opposite sides of the wrapped hay bales to controllably cut the layered material.   
     
     
       6. A system according to claim 1 wherein the conduit has tapered exterior walls. 
     
     
       7. A system according to claim 1 wherein the conduit comprises multiple prongs provided on multiple sides of the wrapped hay bales, individual prongs tapering in width from a first end to a second end. 
     
     
       8. A system according to claim 1 wherein the conduit comprises four prongs provided on four sides of the wrapped hay bales, individual prongs tapering in both thickness and width from a first end to a second end. 
     
     
       9. A system according to claim 1 wherein the hay bale has a length taken along the feed axis; and the conduit is dimensioned to extend along the feed axis at least approximately 75% of the length of the hay bale.   
     
     
       10. A system according to claim 1 wherein the hay bale has a length taken along the feed axis; and the multiple layers of material wrapped about the bale have an overall width greater than the length of the hay bale such that ends of the bale are overlapped by the material.   
     
     
       11. A system according to claim 1 wherein the wrapping means comprises: a frame;   a wheel rotatably mounted to the frame to rotate about the feed axis;   drive means for rotating the wheel;   multiple pairs of spool shafts mounted to the wheel for supporting associated spools of material; and   multiple discharging roller sets for corresponding pairs of spool shafts to guide sheets of material from the associated spools toward the conduit, individual discharging roller sets having at least three rollers to prestretch the sheets of material prior to wrapping them around the hay bales.   
     
     
       12. A system according to claim 1 further comprising: a press provided upstream of the wrapping machine for compressing a quantity of hay within a chamber to form individual hay bales, the press having means for transferring the compressed hay bales from the chamber to the wrapping machine where the hay bales are extruded through the conduit along the feed axis;   the hay bales at the wrapping machine being stationary during a period in which upstream hay bales are being compressed within the press chamber; and   the wrapping machine continuously applying layers of material while the hay bales in the wrapping machine are stationary to apply a selected number of layers to the hay bales.   
     
     
       13. An apparatus for wrapping sheets of material around compressed bales of hay, comprising: a frame;   a hollow conduit fixedly mounted to the frame, the conduit defining a passage through which hay bales are extruded along a feed axis, the conduit having four prong means for maintaining the compressed nature of the bales at a discharge end thereof provided on four sides of the hay bales, with individual prongs tapering in both thickness and width from a first end at the discharge end of the conduit to a second end downstream of the conduit discharge end;   a wheel rotatably mounted to the frame to rotate about the feed axis;   drive means for rotating the wheel;   at least one spool shaft mounted to the wheel for supporting a spool of material; and   the wheel dispensing a sheet of material from the spool as the wheel rotates around the feed axis to wrap the sheet of material around the hay bales as the hay bales are extruded through the conduit.   
     
     
       14. An apparatus according to claim 13 wherein a hay bale extruded through the conduit has a length taken along the feed axis; and the conduit is dimensioned to extend along the feed axis at least approximately 75% of the length of the hay bale.